Systems and Methods for Implementing Flexible Members Including Integrated Tools Made from Metallic Glass-Based Materials

ABSTRACT

Systems and methods in accordance with embodiments of the invention implement flexible members that include integrated tools made from metallic glass-based materials. In one embodiment, a structure includes: a flexible member characterized by an elongated geometry and an integrated tool disposed at one end of the elongated geometry; where the flexible member includes a metallic glass-based material.

CROSS-REFERENCE TO RELATED APPLICATIONS

The current application is a continuation of U.S. application Ser. No.15/069,381, filed Mar. 14, 2016, which application claims priority toU.S. Provisional Application No. 62/132,325, filed Mar. 12, 2015, thedisclosures of which are incorporated herein by reference in theirentireties.

STATEMENT OF FEDERAL FUNDING

The invention described herein was made in the performance of work undera NASA contract NNN12AA01C, and is subject to the provisions of PublicLaw 96-517 (35 USC 202) in which the Contractor has elected to retaintitle.

FIELD OF THE INVENTION

The present invention generally relates to the implementation offlexible members including integrated tools made from metallicglass-based materials.

BACKGROUND

Engineered mechanisms often rely on a variety of componentscharacterized by intentionally distinct geometries and/or mechanicalproperties. Thus, for instance, U.S. Pat. No. 8,789,629 (the '629patent) discloses terrain traversing devices having wheels with includedmicrohooks. More specifically, the abstract of the '629 patent reads:

-   -   A terrain traversing device includes an annular rotor element        with a plurality of co-planar microspine hooks arranged on the        periphery of the annular rotor element. Each microspine hook has        an independently flexible suspension configuration that permits        the microspine hook to initially engage an irregularity in a        terrain surface at a preset initial engagement angle and        subsequently engage the irregularity with a continuously varying        engagement angle when the annular rotor element is rotated for        urging the terrain traversing device to traverse a terrain        surface.

The '629 patent proposes that the referenced microspine wheel assemblycan be made out of any of a variety of suitable materials including, forexample steel and/or a hard plastic. The disclosure of the '629 patentis hereby incorporated by reference in its entirety.

SUMMARY OF THE INVENTION

Systems and methods in accordance with embodiments of the inventionimplement flexible members that include integrated tools made frommetallic glass-based materials. In one embodiment, a structure includes:a flexible member characterized by an elongated geometry and anintegrated tool disposed at one end of the elongated geometry; where theflexible member includes a metallic glass-based material.

In another embodiment, the integrated tool is a hook.

In yet another embodiment, the metallic glass-based material is ametallic glass matrix composite material.

In still another embodiment, the metallic glass-based material ischaracterized by a fracture toughness of greater than approximately 80MPa·m^(1/2).

In still yet another embodiment, flexible member is characterized inthat it is fully amorphous.

In a further embodiment, the metallic glass-based material ischaracterized in that it has an elastic limit of greater thanapproximately 1%.

In a still further embodiment, the metallic glass-based material ischaracterized in that it has an elastic limit of greater thanapproximately 1.5%.

In a yet further embodiment, the metallic glass-based material ischaracterized in that it has an elastic limit of greater thanapproximately 2%.

In a still yet further embodiment, the flexible member is characterizedby a thickness of less than approximately three times the size of theplastic zone radius of the metallic glass-based material.

In another embodiment, the flexible member is characterized by athickness of less than approximately 1.5 mm.

In yet another embodiment, the flexible member defines a plurality ofextensions including a plurality of integrated tools disposed at one endof respective extensions.

In still another embodiment, a wheel assembly includes: at least onerotor element; a plurality of flexible members, each characterized by anelongated geometry and an integrated tool at the end of the elongatedgeometry; where: at least one of the plurality of flexible membersincludes a metallic glass-based material; and the plurality of flexiblemembers are approximately uniformly distributed around at least onerotor element such that the aggregate of the at least one rotor elementand the plurality of flexible members can viably function as a wheel.

In still yet another embodiment, the integrated tool is a hook.

In a further embodiment, the metallic glass-based material of at leastone flexible member is characterized by a fracture toughness of greaterthan approximately 80 MPa·m^(1/2).

In a yet further embodiment, a method of forming a flexible memberincluding an integrated tool, includes: forming a metallic glass-basedmaterial into an elongated geometry; and deforming the elongatedgeometry to define a tool at one end of the elongated geometry when thetemperature of the metallic glass-based material is lower than itsrespective glass transition temperature; where the metallic glass-basedmaterial is characterized by a fracture toughness of greater thanapproximately 80 MPa·m^(1/2).

In a still further embodiment, the integrated tool is a hook.

In a still yet further embodiment, the hook is defined by an angle ofgreater than approximately 80° relative to the remainder of the flexiblemember.

In another embodiment, forming the metallic glass-based material into anelongated geometry includes shearing an elongated geometry from a sheetof the metallic glass-based material.

In still another embodiment, the thickness of the elongated geometry isless than approximately three times the size of the plastic zone radiusof the metallic glass-based material.

In yet another embodiment, the thickness of the elongated geometry isless than approximately 1.5 mm.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B illustrate a conventional wheel assembly that can beimplemented within a terrain traversing devices.

FIGS. 2A-2E schematically illustrate constructing a flexible memberincluding an integrated tool disposed at one end of the flexible memberfrom a metallic glass-based material in accordance with certainembodiments of the invention.

FIG. 3 illustrates an alternative geometry for a flexible memberincluding a plurality of integrated tools made from a metallicglass-based material that can be implemented in accordance with certainembodiments of the invention.

FIG. 4 illustrates a process for implementing a structure including anannular rotor element and a plurality of flexible members includingintegrated tools made from metallic glass-based materials in accordancewith certain embodiments of the invention.

FIGS. 5A-5B illustrate the incorporation of flexible members includingintegrated tools made from metallic glass-based materials with anannular rotor element in accordance with certain embodiments of theinvention.

FIGS. 6A-6D illustrate the elasticity of flexible members made frommetallic glass-based materials in accordance with certain embodiments ofthe invention.

FIGS. 7A-7B illustrate the manufacture of a wheel assembly incorporatinga plurality of flexible members including integrated tools made frommetallic glass-based materials in accordance with certain embodiments ofthe invention.

FIGS. 8A-8D illustrates a terrain traversing vehicle incorporating wheelassemblies including flexible members that include integrated tools madefrom metallic glass-based materials in accordance with certainembodiments of the invention.

DETAILED DESCRIPTION

Turning now to the drawings, systems and methods for implementingflexible members that include integrated tools made from metallicglass-based materials are illustrated. In many embodiments of theinvention, the flexible members are elongated and include tools disposedat one end of its elongated geometry. In many embodiments, theintegrated tool is a hook. In a number of embodiments, flexible membersthat include integrated hooks are disposed around the periphery of anannular rotor element. In numerous embodiments, either one or aplurality of such annular rotor elements are configured to operate as awheel assembly.

For context, FIGS. 1A-1B illustrate a conventional wheel assembly inaccordance with the disclosure of the '629 patent. In particular, FIG.1A illustrates a wheel assembly 102 that includes an annular rotorelement 104 with attached flexible member/microspine hook assemblies106, which themselves each include a flexible member 108 and an attachedmicrospine hook 110. It is depicted that the microspine hooks 110 areattached to the flexible members 108 via a polymer 112. The flexiblemember/microspine hook assemblies 106 are distributed around theperiphery of the annular rotor element 104. The flexible members 108conventionally have been made from a flexible metal, such as springsteel or nitinol. The microspine hooks have conventionally beenimplemented via standard steel fishing hooks. FIG. 1B illustrates theflexibility of the flexible suspensions 108. As disclosed in the '629patent, the depicted wheel assembly can be incorporated in a terraintraversing device, such that the wheels can operate to facilitate thetraversal of rigorous terrain. In particular, the respective flexiblesuspensions permit respective microspine hooks to initially engage anirregularity in a terrain surface at a preset initial engagement anglewhen the annular rotor element is rotated for urging the terraintraversing device to traverse a terrain surface.

Although configurations such as those depicted in FIGS. 1A-1Bmanufactured from combinations of steel, nitinol, and/or polymer can beeffective, there exists room for improvement. For example, the bondingof a distinct hook to a typical metallic flexible member using a polymercan define a weakness within the assembly. In particular, thepolymer/microspine hook bonding can be susceptible to failure in theseconfigurations. Such assemblies can benefit from a unibody construction,and more particularly from the incorporation of metallic glass-basedmaterials.

Metallic glasses, also known as amorphous alloys, embody a relativelynew class of materials that is receiving much interest from theengineering and design communities. Metallic glasses are characterizedby their disordered atomic-scale structure in spite of their metallicconstituent elements—i.e. whereas conventional metallic materialstypically possess a highly ordered atomic structure, metallic glassmaterials are characterized by their disordered atomic structure.Notably, metallic glasses typically possess a number of useful materialproperties that can allow them to be implemented as highly effectiveengineering materials. For example, metallic glasses are generally muchharder than conventional metals, and are generally tougher than ceramicmaterials. They are also relatively corrosion resistant, and, unlikeconventional glass, they can have good electrical conductivity.Importantly, metallic glass materials lend themselves to relatively easyprocessing in certain respects. For example, the forming of metallicglass materials can be compatible with injection molding processes.Thus, for example, metallic glass compositions can be cast into desiredshapes.

Nonetheless, the practical implementation of metallic glasses presentscertain challenges that limit their viability as engineering materials.In particular, metallic glasses are typically formed by raising ametallic alloy above its melting temperature, and rapidly cooling themelt to solidify it in a way such that its crystallization is avoided,thereby forming the metallic glass. The first metallic glasses requiredextraordinary cooling rates, e.g. on the order of 10⁶ K/s, and werethereby limited in the thickness with which they could be formed.Indeed, because of this limitation in thickness, metallic glasses wereinitially limited to applications that involved coatings. Since then,however, particular alloy compositions that are more resistant tocrystallization have been developed, which can thereby form metallicglasses at much lower cooling rates, and can therefore be made to bemuch thicker (e.g. greater than 1 mm). These metallic glass compositionsthat can be made to be thicker are known as ‘bulk metallic glasses’(“BMGs”). As can be appreciated, such BMGs can be better suited forinvestment molding operations.

In addition to the development of BMGs, ‘bulk metallic glass matrixcomposites’ (BMGMCs) have also been developed. BMGMCs are characterizedin that they possess the amorphous structure of BMGs, but they alsoinclude crystalline phases of material within the matrix of amorphousstructure. For example, the crystalline phases can exist in the form ofdendrites. The crystalline phase inclusions can impart a host offavorable materials properties on the bulk material. For example, thecrystalline phases can allow the material to have enhanced ductility,compared to where the material is entirely constituted of the amorphousstructure. BMGs and BMGMCs can be referred to collectively as BMG-basedmaterials. Similarly, metallic glasses, metallic glasses that includecrystalline phase inclusions, BMGs, and BMGMCs can be referred tocollectively as metallic glass-based materials or MG-based materials.

The potential of metallic glass-based materials continues to beexplored, and developments continue to emerge. For example, in U.S.patent application Ser. No. 13/928,109, D. Hofmann et al. disclose theimplementation of metallic glass-based materials in macroscale gears.The disclosure of U.S. patent application Ser. No. 13/928,109 is herebyincorporated by reference in its entirety, especially as it pertains tometallic glass-based materials, and their implementation in macroscalegears. Likewise, in U.S. patent application Ser. No. 13/942,932, D.Hofmann et al. disclose the implementation of metallic glass-basedmaterials in macroscale compliant mechanisms. The disclosure of U.S.patent application Ser. No. 13/942,932 is hereby incorporated byreference in its entirety, especially as it pertains to metallicglass-based materials, and their implementation in macroscale compliantmechanisms. Moreover, in U.S. patent application Ser. No. 14/060,478, D.Hofmann et al. disclose techniques for depositing layers of metallicglass-based materials to form objects. The disclosure of U.S. patentapplication Ser. No. 14/060,478 is hereby incorporated by referenceespecially as it pertains to metallic glass-based materials, andtechniques for depositing them to form objects. Furthermore, in U.S.patent application Ser. No. 14/163,936, D. Hofmann et al., disclosetechniques for additively manufacturing objects so that they includemetallic glass-based materials. The disclosure of U.S. patentapplication Ser. No. 14/163,936 is hereby incorporated by reference inits entirety, especially as it pertains to metallic glass-basedmaterials, and additive manufacturing techniques for manufacturingobjects so that they include metallic glass-based materials.Additionally, in U.S. patent application Ser. No. 14/177,608, D. Hofmannet al. disclose techniques for fabricating strain wave gears usingmetallic glass-based materials. The disclosure of U.S. patentapplication Ser. No. 14/177,608 is hereby incorporated by reference inits entirety, especially as it pertains to metallic glass-basedmaterials, and their implementation in strain wave gears. Moreover, inU.S. patent application Ser. No. 14/178,098, D. Hofmann et al., discloseselectively developing equilibrium inclusions within an objectconstituted from a metallic glass-based material. The disclosure of U.S.patent application Ser. No. 14/178,098 is hereby incorporated byreference, especially as it pertains to metallic glass-based materials,and the tailored development of equilibrium inclusions within them.Furthermore, in U.S. patent application Ser. No. 14/252,585, D. Hofmannet al. disclose techniques for shaping sheet materials that includemetallic glass-based materials, including using localized thermoplasticdeformation and using cold working techniques. The disclosure of U.S.patent application Ser. No. 14/252,585 is hereby incorporated byreference in its entirety, especially as it pertains to metallicglass-based materials and techniques for shaping sheet materials thatinclude metallic glass-based materials, including using localizedthermoplastic deformation and using cold-working techniques.Additionally, in U.S. patent application Ser. No. 14/259,608, D. Hofmannet al. disclose techniques for fabricating structures including metallicglass-based materials using ultrasonic welding. The disclosure of U.S.patent application Ser. No. 14/259,608 is hereby incorporated byreference in its entirety, especially as it pertains to metallicglass-based materials and techniques for fabricating structuresincluding metallic glass-based materials using ultrasonic welding.Moreover, in U.S. patent application Ser. No. 14/491,618, D. Hofmann etal. disclose techniques for fabricating structures including metallicglass-based materials using low pressure casting. The disclosure of U.S.patent application Ser. No. 14/491,618 is hereby incorporated byreference in its entirety, especially as it pertains to metallicglass-based materials and techniques for fabricating structuresincluding metallic glass-based materials using low pressure casting.Furthermore, in U.S. patent application Ser. No. 14/660,730, Hofmann etal. disclose metallic glass-based fiber metal laminates. The disclosureof U.S. patent application Ser. No. 14/660,730 is hereby incorporated byreference in its entirety, especially as it pertains to metallicglass-based fiber metal laminates. Additionally, in U.S. patentapplication Ser. No. 14/971,848, A. Kennett et al. disclose techniquesfor manufacturing gearbox housings made from metallic glass-basedmaterials. The disclosure of U.S. patent application Ser. No.14/971,848, is hereby incorporated by reference in its entirety,especially as it pertains to the manufacture of metallic glass-basedgearbox housings.

Notwithstanding all of these developments, the vast potential ofmetallic glass-based materials has yet to be fully appreciated. Forinstance, the suitability of metallic glass-based materials forimplementation as flexible members that include integrated tools (e.g.the flexible suspension members microspine assemblies discussed in the'629 patent) has yet to be fully explored. Conventionally, thestructures described in the '629 patent have been fabricated fromconventional engineering metals like steel, nitinol, and/or polymers (asdepicted in FIGS. 1A-16). However, these structures can greatly benefitin a number of respects from the incorporation of metallic glass-basedmaterials. For instance, metallic glass-based materials can imbue thewheels with improved fatigue characteristics, improved hardness,improved wear-resistance properties, improved flexibility, improvedcorrosion resistance, improved resilience against harsh environmentalconditions, etc. Thus, for instance, the enhanced flexibility of manyMG-based materials (e.g. having an elastic limit of up to 2% or morecompared with steel which typically has an elastic limit of on the orderof 1%) can allow better performance in terrain traversing applications.At the same time, the inherent hardness of many MG-based materials canfurther provide for improved hook performance; e.g. the hooks may notwear as easily as they interact with rigorous terrain. Metallicglass-based materials can also be readily cast or otherwisethermoplastically formed into any of a variety of complex geometries.Whereas conventionally, the fabrication of these structures involvedadjoining various components to achieve the desired geometry, metallicglass-based materials can viably be ‘net shape’ cast (or ‘near netshape’ cast) into these structures; this can greatly enhancemanufacturing efficiency. Methods for fabricating flexible members withintegrated tools that include metallic glass-based materials are nowdiscussed below.

Methods for Implementing Flexible Members Including Integral Tools fromMetallic Glass-Based Materials

In many embodiments of the invention, flexible members includingintegral tools are fabricated from metallic glass-based materials. Anysuitable manufacturing technique can be utilized to form the flexiblemember in accordance with embodiments of the invention. For example, inmany embodiments, metallic glass-based materials are cold worked toshape them into the desired geometry—e.g. they are shaped attemperatures less than or equal to approximately room temperature (e.g.72° F.). More broadly stated, cold-working can be said to occur when anMG-based material is shaped at a temperature less than its respectiveglass transition temperature. Thus for instance, FIGS. 2A-2E illustratethe fabrication of a flexible member including an integrated tool from ametallic glass-based material via cold-forming in accordance with anembodiment of the invention. In particular, FIG. 2A illustrates ametallic glass-based material to be formed into the desired structure.In the illustrated embodiment, the MG-based material is DV1. FIG. 2Billustrates that the metallic glass-based composition has been slicedinto a thin sheet characterized by a thickness of 1 mm. FIG. 2Cillustrates that the metallic glass-based composition has been furthersliced to create an elongated geometry. FIG. 2D illustrates that the endis then bent to an angle greater than approximately 80° to create thedesired geometry; more particularly, the bent end defines a hook that isthe integrated tool. The inherent fracture toughness of DV1 allows it toaccommodate the depicted extreme bending. FIG. 2E illustrates the finalgeometry of two created structures. Thus, contrary to what may have beenpreviously believed, it is illustrated that it is possible to bend (viacold working) an elongated geometry—made from a MG-based material—to anextreme angle without worrying about compromising the structuralintegrity of the piece. This is largely a function of the inherentfracture toughness of the respective metallic glass-based material.Accordingly, while cold-forming to this degree may be suitable forcertain MG-based materials, it may not be suitable for all MG-basedmaterials. A respective material must have at least a minimum fracturetoughness in order to be able to withstand cold-working to this degree.Additionally, a MG-based material's ability to be cold-worked asdescribed may be a function of the thickness of the MG-based materialflexible member. Thus, for instance, in many embodiments a flexiblemember to be cold worked to form the integrated tool is characterized bya thickness of less than 1.5 mm. Cold forming can enable the easymanufacture of this useful geometry.

While cold-working a flexible member to form an integrated tool from ametallic glass-based material has been illustrated, it should be clearthat any of a variety of processes can be implemented to form a flexiblemember including an integrated tool in accordance with embodiments ofthe invention. For example, in many embodiments, localized thermoplasticdeformation processes as disclosed in U.S. patent application Ser. No.14/252,585 incorporated by reference above are implemented, e.g. theflexible member can be bent when a region of the flexible member isabove its respective glass transition temperature to define the hook. Inmany embodiments, direct casting techniques are utilized; casting can bea particularly efficient manufacturing strategy for the bulk fabricationof the described structures. Any suitable manufacturing technology canbe implemented in accordance with embodiments of the invention.

Moreover, note that any suitable MG-based composition can be utilized toform a flexible member having an integrated tool in accordance withembodiments of the invention; embodiments of the invention are notlimited to a particular composition. For example, in many instances, theutilized alloy composition is a composition that is based on one of: Ti,Zr, Cu, Ni, Fe, Pd, Pt, Ag, Au, Al, Hf, W, Ti—Zr—Be, Cu—Zr, Zr—Be,Ti—Cu, Zr—Cu—Ni—Al, Ti—Zr—Cu—Be and combinations thereof. In the instantcontext, the term ‘based on’ can be understood to mean that thespecified element(s) are present in the greatest amount relative to anyother present elements. Additionally, within the context of the instantapplication, the term “MG-based composition” can be understood referencean element, or aggregation of elements, that are capable of forming ametallic glass-based material (e.g. via being exposed to a sufficientlyrapid, but viable, cooling rate). While several examples of suitablemetallic glass-based materials are listed above, it should be reiteratedthat any suitable metallic glass-based composition can be incorporatedin accordance with embodiments of the invention; for example, any of themetallic glass-based compositions listed in the disclosures cited andincorporated by reference above can be implemented. As alluded to above,in many embodiments, the implemented MG-based composition is based onthe manufacturing technique to be applied. For example, where coldworking will be used to shape the MG-based composition, a MG-basedcomposition that is capable of forming a MG-based material characterizedby a relatively high fracture toughness can be implemented. In a numberof embodiments, the MG-based material is characterized by a fracturetoughness of greater than approximately 80 MPa·m^(1/2). In severalembodiments, the MG-based material is characterized by a fracturetoughness of greater than approximately 100 MPa·m^(1/2). In manyembodiments, the MG-based composition is implemented in the form of amatrix composite characterized by a particularly high fracture toughness(e.g. greater than approximately 80 MPa·m^(1/2) or approximately 100MPa·m^(1/2)). In a number of embodiments, the MG-based material that isto be formed into a flexible member via cold-forming is characterized bya thickness that is less than approximately three times the thickness ofthe plastic zone radius of the respective MG-based material. In numerousembodiments, the MG-based material that is to be formed into a flexiblemember via cold-forming is characterized by a thickness that is lessthan plastic zone radius of the respective MG-based material. In severalembodiments, the MG-based material is characterized by a thickness ofless than approximately 1.5 mm. These thicknesses can facilitate thedesired formability. In many instances, the particular MG-basedcomposition to be implemented is based on an assessment of theanticipated operating environment for the flexible member. For example,where it desired that the flexible member be relatively less massive, atitanium based MG-based material can be implemented. In many instances,the selection of the MG-based material to be implemented is based on thedesire for one of: environmental resilience, toughness, wear resistance,hardness, density, machinability, and combinations thereof. In numerousembodiments, the MG-based material to be implemented is based on thedesire to have relatively high resistance to wear (which can becorrelated with hardness) and relatively high flexibility (which can becorrelated with elastic strain limit). In many embodiments, the hardnessof the MG-based material to be implemented is characterized by a valuegreater than approximately 50 Rc according to the Rockwell scale. In anumber of embodiments, the MG-based material to be implemented has anelastic limit greater than approximately 1%. For reference, Tables 1-6list materials data that can be relied on in selecting a metallicglass-based composition to be implemented. Any suitable MG-basedmaterial listed in the tables below can be implemented in accordancewith various embodiments of the invention.

TABLE 1 Material Properties of MG-Based Materials relative to HeritageEngineering Materials Density Stiffness, E Tensile Yield Tensile UTSElastic Limit Specific Hardness Material (g/cc) (GPa) (MPa) (MPa) (%)Strength (HRC) SS 15500 H1024 7.8 200 1140 1170 <1 146 36 Ti—6Al—4V STA4.4 114 965 1035 <1 219 41 Ti—6Al—6V—4Sn STA 4.5 112 1035 1100 <1 230 42Nitronic 60 CW 7.6 179 1241 1379 <1 163 40 Vascomax C300 8.0 190 18971966 <1 237 50 Zr-BMG 6.1 97 1737 1737 >1.8 285 60 Ti-BMGMC 5.2 94 13621429 >1.4 262 51 Zr-BMGMC 5.8 75 1096 1210 >1.4 189 48

TABLE 2 Material Properties of Select MG-Based Materials as a functionof Composition BMG bcc ρ σ_(y) σ_(max) ε_(y) E T_(x) name atomic %weight % (%) (%) (g/cm³) (MPa) (MPa) (%) (GPa) (K) DV2Ti₄₄Zr₂₀V₁₂Cu₅Be₁₅ Ti_(41.9)Zr_(35.3)V_(12.1)Cu_(6.3)Be_(3.4) 70 30 5.131597 1614 2.1 94.5 956 DV1 Ti₄₈Zr₃₀V₁₂Cu₅Be₁₅Ti_(44.3)Zr_(35.2)V_(11.8)Cu_(6.1)Be_(2.6) 53 47 5.15 1362 1429 2.3 9.2955 DV3 Ti₅₆Zr₁₈V₁₀Cu₄Be₁₂ Ti_(51.6)Zr_(31.6)V_(9.8)Cu_(4.9)Be_(2.1) 4654 5.08 1308 1309 2.2 84.0 951 DV4 Ti₆₂Zr₁₅V₁₀Cu₄Be₉Ti_(57.3)Zr_(26.4)V_(9.8)Cu_(4.9)Be_(1.6) 40 60 5.03 1086 1089 2.1 83.7940 DVAl1 Ti₆₀Zr₁₆V₉Cu₃Al₃Be₉Ti_(55.8)Zr_(38.4)V_(8.9)Cu_(3.7)Al_(1.6)Be_(1.5) 31 69 4.97 1166 11892.0 84.2 901 DVAl2 Ti₆₇Zr₁₁V₁₀Cu₅Al₂Be₂Ti_(54.2)Zr_(39.5)V_(9.5)Cu_(6.2)Al₁Be_(0.5) 20 80 4.97 990 1000 2.078.7 998 Ti-6-4a Ti_(86.1)Al_(10.3)V_(3.6) Ti₉₀Al₆V₄ (Grade 5 Annealed)na na 4.43 754 882 1.0 113.8 1877 Ti-6-4s Ti_(86.1)Al_(10.3)V_(3.5)[Ref] Ti₉₈Al₆V₄ (Grade 5 STA) na na 4.43 1100 1170 −1 114.0 1877 CP-TiTi₁₀₀ Ti₁₀₀ (Grade 2) na na 4.51 380 409 0.7 105.0 −1930

TABLE 3 Material Properties of Select MG-Based Materials as a functionof Composition σ_(max) E_(lot) σ_(y) ε_(y) E ρ G CIT RoA Alloy (MPa) (%)(MPa) (%) (GPa) (g/cm³) (GPa) (J) (%) υZr_(36.6)Ti_(31.4)Nb₇Cu_(5.9)Be_(19.1) (DH1) 1512 9.58 1474 1.98 84.35.6 30.7 26 44 0.371 Zr_(38.3)Ti_(32.9)Nb_(7.3)Cu_(6.2)Be_(15.3) (DH2)1411 10.0 1567 1.92 79.2 5.7 28.8 40 50 0.373Zr_(39.6)Ti_(33.9)Nb_(7.6)Cu_(6.4)Be_(12.5) (DH3) 1210 13.10 1096 1.6275.3 5.8 27.3 45 46 0.376 Zr_(41.2)Ti_(13.8)Cu_(12.5)Ni₁₀Be_(22.5)(Vitreloy 1) 1737 1.98 — — 97.2 6.1 35.9 8 0 0.355Zr_(56.2)Ti_(13.8)Nb_(5.0)Cu_(6.9)Ni_(5.6)Be_(12.5) (LM2) 1302 5.49 10461.48 78.8 6.2 28.6 24 22 0.375

TABLE 4 Material Properties as a Function of Composition and Structure,where A is Amorphous, X, is Crystalline, and C is Composite A/X/C 2.0HvE (GPa) (CuZr₄₂Al₇Be₁₀)Nb₃ A 626.5 108.5 (CuZr₄₆Al₅Y₂)Nb₃ A 407.4 76.9(CuZrAl₇Be₅)Nb₃ A 544.4 97.8 (CuZrAl₇Be₇)Nb₃ A 523.9 102.0Cu₄₀Zr₄₀Al₁₀Be₁₀ A 604.3 114.2 Cu₄₁Zr₄₀Al₇Be₇Co₅ C 589.9 103.5Cu₄₂Zr₄₁Al₇Be₇Co₃ A 532.4 101.3 Cu_(47.5)Zr₄₈Al₄Co_(0.5) X 381.9 79.6Cu₄₇Zr₄₆Al₅Y₂ A 409.8 75.3 Cu₅₀Zr₅₀ X 325.9 81.3 CuZr₄₁Al₇Be₇Cr₃ A 575.1106.5 CuZrAl₅Be₅Y₂ A 511.1 88.5 CuZrAl₅Ni₃Be₄ A 504.3 95.5 CuZrAl₇ X510.5 101.4 CuZrAl₇Ag₇ C 496.1 90.6 CuZrAl₇Ni₅ X 570.0 99.2Ni₄₀Zr_(28.5)Ti_(16.5)Be₁₅ C 715.2 128.4 Ni₄₀Zr_(28.5)Ti_(16.5)Cu₁₅Al₁₀X 627.2 99.3 Ni₄₀Zr_(28.5)Ti_(16.5)Cu₁₅Be₁₀ C 668.2 112.0Ni₅₆Zr₁₇Ti₁₃Si₂Sn₃Be₉ X 562.5 141.1 Ni₅₆Zr₁₈Ti₁₄Si₂Sn₃Be₆ X 637.3 139.4Ti_(33.18)Zr_(30.51)Ni_(5.33)Be_(22.88)Cu_(8.1) A 486.1 96.9Ti₄₀Zr₂₅Be₃₀Cr₅ A 465.4 97.5 Ti₄₀Zr₂₅Ni₈Cu₉Be₁₈ A 544.4 101.1Ti₄₅Zr₁₆Ni₉Cu₁₀Be₂₀ A 523.1 104.2 Vit 1 A 530.4 95.2 Vit 105(Zr_(52.5)Ti₅Cu_(17.9)Ni_(14.6)Al₁₀) A 474.4 88.5 Vit 106 A 439.7 83.3Zr₅₅Cu₃₀Al₁₀Ni₅ A 520.8 87.2 Zr₆₅Cu_(17.5)Al_(7.5)Ni₁₀ A 463.3 116.9 DH1C 391.1 84.7 GHDT (Ti₃₀Zr₃₅Cu_(8.2)Be_(26.8)) A 461.8 90.5

TABLE 5 Fatigue Characteristics as a Function of Composition FractureFatigue Strength Geometry Loading Frequency Limit Fatigue Material (MPa)(mm) mode (Hz) R-ratio (MPa) ratioZr_(56.2)Cu_(6.9)Ni_(5.6)Ti_(13.8)Nb_(5.0)Be_(12.5) 1480 3 × 3 × 30 4PB25 0.1 ~296 0.200 Composites Zr_(41.2)Cu_(12.5)Ni₁₀Ti_(13.8)Be_(22.5)1900 3 × 3 × 50 4PB 25 0.1 ~152 0.080Zr_(41.2)Cu_(12.5)Ni₁₀Ti_(13.8)Be_(22.5) 1900 2 × 2 × 60 3PB 10 0.1 7680.404 Zr_(41.2)Cu_(12.5)Ni₁₀Ti_(13.8)Be_(22.5) 1900 2 × 2 × 60 3PB 100.1 359 0.189 Zr₄₄Ti₁₁Ni₁₀Cu₁₀Be₂₅ 1900 2.3 × 2.0 × 85 4PB 5-20 0.3 5500.289 Zr₄₄Ti₁₁Ni₁₀Cu₁₀Be₂₅ 1900 2.3 × 2.0 × 85 4PB 5-20 0.3 390 0.205Zr_(52.5)Cu_(17.9)Al₁₀Ni_(14.6)Ti₅ 1700 3.5 × 3.5 × 30 4PB 10 0.1 8500.500 (Zr₅₈Ni_(13.6)Cu₁₈Al_(10.4))₉₉Nb₁ 1700 2 × 2 × 25 4PB 10 0.1 5590.329 Zr₅₅Cu₃₀Ni₅Al₁₀ 1560  2 × 20 × 50 Plate 40 0.1 410 0.263 bend

TABLE 6 Fatigue Characteristics as a Function of Composition FractureFatigue Strength Geometry Loading Frequency Limit Fatigue Material (MPa)(mm) mode (Hz) R-ratio (MPa) ratioZr_(56.2)Cu_(6.9)Ni_(5.6)Ti_(13.8)Nb_(5.0)Be_(12.5) 1480 02.98 TT 10 0.1239 0.161 Composites Zr₅₅Cu₃₀Al₁₀Ni₅ Nano 1700 2 × 4 × 70 TT 10 0.1 ~3400.200 Zr_(41.2)Cu_(12.5)Ni₁₀Ti_(13.8)Be_(22.5) 1850 Ø2.98 TT 10 0.1 7030.380 Zr_(41.2)Cu_(12.5)Ni₁₀Ti_(13.8)Be_(22.5) 1850 Ø2.98 TT 10 0.1 6150.332 Zr_(41.2)Cu_(12.5)Ni₁₀Ti_(13.8)Be_(22.5) 1850 Ø2.98 TT 10 0.1 5670.306 Zr_(41.2)Cu_(12.5)Ni₁₀Ti_(13.8)Be_(22.5) 1900 — CC 5 0.1 ~10500.553 Zr_(41.2)Cu_(12.5)Ni₁₀Ti_(13.8)Be_(22.5) 1900 — TC 5 ~1 ~150 0.079Zr₅₀Cu₄₀Al₁₀ 1821 Ø2.98 TT 10 0.1 752 0.413 Zr₅₀Cu₃₀Al₁₀Ni₁₀ 1900 Ø2.98TT 10 0.1 865 0.455 Zr₅₀Cu₃₀Al₁₀Pd₃ 1899 Ø2.98 TT 10 0.1 983 0.518Zr₅₀Cu₃₀Al₁₀Pd₃ 1899 Ø2.98 TT 10 0.1 ~900 0.474Zr_(52.5)Cu_(17.9)Al₁₀Ni_(14.6)Ti₅ 1660 6 × 3 × 15 TT 1 0.1 — —Zr_(52.5)Cu_(17.9)Al₁₀Ni_(14.6)Ti₅ 1700 Ø2.98 TT 10 0.1 907 0.534Zr₅₉Cu₂₀Al₁₀Ni₈Ti₃ 1580  6 × 3 × 1.5 TT 1 0.1 — — Zr₆₅Cu₁₅Al₁₀Ni₁₀ 13003 × 4 × 16 TT 20 0.1 ~280 0.215 Zr₅₅Cu₃₀Al₁₀Ni₅ 1560 1 × 2 × 5  TT 0.130.5 — —

Furthermore, although a particular geometry for a flexible member withan integrated tool is illustrated and described with respect to FIGS.2A-2E, it should be clear that any suitable geometry for a flexiblemember including an integrated tool can be incorporated in accordancewith embodiments of the invention. For example, in many embodiments, aflexible member includes a plurality of extensions and a plurality ofintegrated tools. Thus, for instance, FIG. 3 illustrates a geometry fora flexible member including a plurality of extensions with a pluralityof integrated tools in accordance with certain embodiments of theinvention. As can be appreciated from the discussion above, any suitablemanufacturing techniques can be used to implement the depicted geometry.For example, the depicted geometry could be cast from a MG-basedcomposition in accordance with embodiments of the invention.

In many embodiments, the flexible members described above areincorporated within the context of a terrain traversing vehicle asdisclosed in the terrain traversing devices disclosed in the '629application. Thus, for example, FIG. 4 illustrates a process forimplementing a wheel including microhooks that can be incorporatedwithin a terrain traversing device as disclosed in the '629 patent. Inparticular, FIG. 4 illustrates that the process 400 includes forming 410a plurality of flexible members that include integrated hooks frommetallic glass-based materials. As before, any suitable metallicglass-based material can be incorporated in accordance with embodimentsof the invention, including any material referenced above. Additionally,any suitable manufacturing technique can be used to form the flexiblemembers from the metallic glass-based materials, e.g. cold forming ordirect casting. The method 400 further includes affixing 420 theplurality of formed flexible members to an annular rotor element. Anysuitable affixing technique can be implemented in accordance withembodiments of the invention. For example, in many embodiments, theflexible member is welded to the annular rotor element. In a number ofembodiments, a rapid capacitive discharge technique is utilized to affixthe flexible member to the annular rotor element. FIGS. 5A-5Bschematically illustrate using a rapid capacitive discharge technique toaffix the flexible member to an annular rotor element in accordance withcertain embodiments of the invention. In particular, FIG. 5A diagramsusing rapid capacitive discharge to affix a flexible member 502 to anannular rotor element 504 in accordance with an embodiment of theinvention. FIG. 5B illustrates an annular rotor element including aplurality of flexible members in accordance with an embodiment of theinvention.

Notably, metallic glass-based materials are often characterized by theirhigh elastic limits. For example, whereas conventional metals haveelastic limits on the order of 1%, metallic glass-based materials canhave elastic limits as high as 2% or more. This high elasticity canallow them to be viably implemented within the terrain traversingdevices disclosed in the '629 patent. FIGS. 6A-6D visually illustratethe flexibility that flexible members made from metallic glass-basedmaterials can be made to possess.

FIGS. 7A-7B illustrate the formation of a wheel including a pluralityflexible members with integrated hooks made from metallic glass-basedmaterials in accordance with embodiments of the invention. Inparticular, FIG. 7A illustrates a plurality of annular rotor elementsincluding a plurality of flexible members made from metallic glass-basedmaterials. FIG. 7B illustrates an assembled wheel incorporated theplurality of annular rotor elements and associated flexible members. Inparticular, the annular rotor elements can be adjoined such thatflexible members are evenly distributed around the adjoined annularrotor elements such that the assembly can operate as a wheel.

FIGS. 8A-8D illustrates a terrain traversing device that incorporateswheels including flexible members with integrated hooks made frommetallic glass-based materials in accordance with embodiments of theinvention. In particular, FIG. 8A illustrates an isometric view of thedevice; FIG. 8B illustrates a view looking down on the device; FIG. 8Cillustrates a side-view of the device; and FIG. 8D illustrates a closeup of the wheel assembly. Notably, the flexible members and integratedhooks made from MG-based materials were sufficiently structurallyintegral to allow the device to crawl vertically up a cinder block.

As can be inferred from the above discussion, the above-mentionedconcepts can be implemented in a variety of arrangements in accordancewith embodiments of the invention. For example, while a hook has beengiven as the example of an integrated tool, any suitable integrated toolcan be implemented in accordance with embodiments of the invention. Forinstance, any implement configured to facilitate mobility or grip/engagea surface can be implemented. Accordingly, although the presentinvention has been described in certain specific aspects, manyadditional modifications and variations would be apparent to thoseskilled in the art. It is therefore to be understood that the presentinvention may be practiced otherwise than specifically described. Thus,embodiments of the present invention should be considered in allrespects as illustrative and not restrictive.

1. A method of forming a flexible member including an integrated tool,comprising: forming a metallic glass-based material into a plurality ofelongated geometries each having a first end and a second end and formedof a metallic glass-based material having a thickness of less thanapproximately three times the size of the plastic zone radius of themetallic glass-based material and an elastic limit of at least 1.0%; anddeforming the elongated geometry to define at least one hook at a firstend of the elongated geometry such that the elongated flexible memberand the hook comprise a unitary body, wherein the temperature of themetallic glass-based material during deformation is lower than itsrespective crystallization temperature.
 2. The method of claim 1,further comprising: attaching the second end of a plurality of elongatedflexible members to a rotor element, such that each elongated flexiblemember is configured to at least partially wrap about the at least onerotor element during operation; and wherein the plurality of elongatedflexible members are distributed around the at least one rotor elementsuch that the aggregate of the plurality of elongated flexible membersform an outer wheel of integrated tools about the at least one rotorelement.
 3. The method of claim 1, wherein the metallic glass-basedmaterial is a metallic glass matrix composite material.
 4. The method ofclaim 1, wherein the metallic glass-based material is characterized by afracture toughness of greater than approximately 80 MPa·m^(1/2).
 5. Themethod of claim 1, wherein the flexible metallic glass-based material isfully amorphous.
 6. The method of claim 1, wherein the metallicglass-based material is characterized in that it has an elastic limit ofgreater than approximately 1.5%.
 7. The method of claim 1, wherein themetallic glass-based material is characterized in that it has an elasticlimit of greater than approximately 2%.
 8. The method of claim 1,wherein the elongated flexible member is characterized by a thickness ofless than approximately 1.5 mm.
 9. The method of claim 1, wherein theelongated flexible member defines a plurality of extensions including aplurality of integrated tools disposed at one end of the respectiveextensions.
 10. The method of claim 1, wherein the hook is defined by anangle of greater than approximately 80° relative to the remainder of theflexible member.
 11. The method of claim 1, wherein forming the metallicglass-based material into an elongated geometry comprises shearing anelongated geometry from a sheet of the metallic glass-based material.12. The method of claim 1, wherein the thickness of the elongatedgeometry is less than approximately three times the size of the plasticzone radius of the metallic glass-based material.
 13. The method ofclaim 1, wherein deforming the elongated geometry comprises heating theelongate geometry and bending at least the first end thereof along thelength thereof, wherein the temperature of the metallic-glass basedmaterial is around its respective glass transition temperature.
 14. Themethod of claim 1, wherein the temperature of the metallic-glass basedmaterial during deforming is below its respective glass transitiontemperature.
 15. A method of terrain traversing device comprising:forming a metallic glass-based material into a plurality of elongatedgeometries each having a first end and a second end and formed of ametallic glass-based material having a thickness of less thanapproximately three times the size of the plastic zone radius of themetallic glass-based material and an elastic limit of at least 1.0%;deforming the elongated geometry to define at least one hook at a firstend of the elongated geometry such that the elongated flexible memberand the hook comprise a unitary body, wherein the temperature of themetallic glass-based material during deformation is lower than itsrespective crystallization temperature; attaching the second end of aplurality of elongated flexible members to a rotor element, such thateach elongated flexible member is configured to at least partially wrapabout the at least one rotor element during operation; and wherein theplurality of elongated flexible members are distributed around the atleast one rotor element such that the aggregate of the plurality ofelongated flexible members form an outer wheel of integrated tools aboutthe at least one rotor element. 16-20. (canceled)